Rebuilding a transmission—especially on a vehicle like the BMW 325, 325i, or 325is—requires a good understanding of automotive mechanics, access to specific tools, and a workspace that can accommodate the job. click here for more details on the download manual…..
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Below, I will outline the process of rebuilding a manual transmission commonly found in these models (specifically the Getrag 260 or ZF S5D 310Z, depending on the year). The process can be complex and may vary slightly depending on the specific transmission model, so always refer to the vehicle’s service manual for precise specifications and procedures.
### Tools and Equipment Needed
1. **Basic Hand Tools**:
– Socket set (metric)
– Wrenches (metric)
– Screwdrivers (flathead and Phillips)
– Pliers
– Hammer
– Torque wrench
2. **Specialized Tools**:
– Transmission jack or lift
– clutch alignment tool
– Snap ring pliers
– Gear pullers
– Micrometer or caliper for measuring tolerances
3. **Cleaning Supplies**:
– Parts cleaner or solvent
– Brushes
– Rags and shop towels
4. **Replacement Parts**:
– Gasket sets
– Seals
– Bearings
– Synchromesh rings (if needed)
– clutch disc and pressure plate (if applicable)
### Step-by-Step Transmission Rebuild Process
#### 1. Preparation
– **Remove the Transmission**:
– Raise the vehicle using a jack and secure it with jack stands.
– Disconnect the battery.
– Drain the transmission fluid using a drain pan.
– Remove the driveshaft and any linkage connected to the transmission.
– Disconnect the transmission from the engine by removing the bell housing bolts.
– Use the transmission jack to safely lower the transmission from the vehicle.
#### 2. Disassembly
– **Remove the Transmission Case**:
– Once on a workbench, remove the bolts securing the transmission case.
– Carefully separate the case halves, ensuring not to damage any internal components.
– **Inspect Internal Components**:
– Take pictures or notes of the assembly for reference.
– Remove gears, shafts, and synchros carefully. Take note of the orientation of each part.
– **Remove Bearings and Seals**:
– Use a bearing puller to remove any bearings.
– Replace all seals to prevent future leaks.
#### 3. Cleaning
– **Clean All Components**:
– Use solvent and a brush to clean all metal surfaces. pay particular attention to the case and any parts that had oil or grease on them.
– Inspect all components for wear, cracks, or damage. Replace anything that shows signs of wear.
#### 4. Inspection
– **Check Tolerances**:
– Measure the gears, bearings, and shafts using a micrometer or caliper to ensure they meet specifications.
– Check synchros for wear and replace if necessary.
#### 5. Reassembly
– **Reinstall Bearings and Seals**:
– Install new bearings and seals in their respective locations, using a light coat of assembly lube to facilitate proper seating.
– **Assemble Gears and Shafts**:
– Reinstall gears, ensuring they are oriented correctly according to your earlier reference notes or photos.
– Insert synchros and ensure they engage properly.
– **Reassemble the Case**:
– Place the two halves of the transmission case together.
– Tighten the case bolts in a crisscross pattern to ensure even pressure.
#### 6. Final Assembly
– **Install New Gasket**:
– Apply a new gasket or RTV sealant where required,
and ensure it is evenly distributed.
– **Attach the Transmission to the Engine**:
– Lift the transmission back into place using the transmission jack.
– Reconnect the bell housing bolts, driveshaft, and any linkage.
– **Reconnect Electrical Components**:
– If your vehicle has sensors or electrical connectors, reconnect them as necessary.
#### 7. Fluids and Testing
– **Fill with Transmission Fluid**:
– Refill the transmission with the appropriate type and amount of fluid, as specified in the service manual.
– **Reconnect Battery**:
– ensure all connections are secure, and reconnect the battery.
#### 8. Testing
– **Test Drive**:
– Start the vehicle and check for any leaks.
– Test drive the car to ensure proper operation of the transmission, paying attention to shifting and any unusual noises.
### Important Considerations
– **Safety First**: always take proper safety precautions, including wearing gloves and safety glasses, and working in a well-ventilated area.
– **Documentation**: Keep your service manual handy for torque specifications and detailed diagrams.
– **Professional Help**: If you’re unfamiliar with transmission work, consider seeking help from a professional mechanic.
This guide provides a general overview of the process for rebuilding a transmission in a BMW 325, 325i, or 325is. The specifics may vary based on the model year and transmission type, so always consult the appropriate service manual for your vehicle.
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